Returnable packaging system

ABSTRACT

A reusable packaging system provides maximum product protection during shipment. The packaging system includes a pallet portion having a container part attached to it, and a cover part intermountable with the container. An inflatable seal is attached to the container and closes the total package when inflated to provide an environmental shield for the packaging system. Interlocking trays are provided for shipping large quantities of component parts. When assembled, the trays prevent vertical and horizontal shifting of the parts during shipment.

United States Patent Repp et al. Sept. 9, 1975 [54} RETURNABLE PACKAGING SYSTEM 3,498.451 3/1970 Foley ct al. 206/386 3,670,880 6 i972 B l t l.... 206 386 [751 lnvemmsl John M Florissam; Frank 3 797 648 351974 .1 204503 Brown, St. Charles, both of M0.

FOREIGN PATENTS OR APPLICATIONS [73} Assignev Emerson Electric Co., St. Louis, Mo.

l 42l,583 ll/l965 France .7 l08/55 [22] Filed: May 10, 1973 211 Appl 359 209 Primary Examiner-William I. Price Assistant Examiner-Joseph M. Moy Attorney, Agent, or FirmPolster and Polster [52] US. Cl. 1. 206/319; 206/386; 206/503; 206/509; 206/522; 206/82l; 220/232 51 Int. (:1. B65D 85/68 ABSTRACT Field of Search 206/3 509. A reusable packaging system provides maximum prod- 206/522, DIG. 30; 217/43 A; 224/421 uct protection during shipment. The packaging system 108/55; 220/46 P includes a pallet portion having a container part attached to it, and a cover part intermountable with the References C'ted container. An inflatable seal is attached to the con- UNITED STATES PATENTS tainer and closes the total package when inflated to 2774490 ll/l956 Strong 206/386 Provide an environmental Shield for the Packaging 2 7s5 g24 3 1957 Reeves 220 4 p tem. Interlocking trays are provided for shipping large 3,225919 l2/l965 Swingle l i i 1 l 4 l t 206/386 quantities of component parts. When assembled, the 3 2. 1 2/1 M ri n i i i y i 1 2 trays prevent vertical and horizontal shifting of the 3403.814 l0/l968 Asenbaueru. 7. 206/509 art during shipment. 3,416,690 lZ/l968 Michael 206/503 3 425 472 2/1969 Marino l08/55 10 Claims, 14 Drawing Figures l f i I 1 1 t 1 1 i i I 9 .50 L 'J Q l J L J 22 5/ Q L J I J I4 I 2 Q L J L J l J L L J L J I 5 E l l h h l' 1 3 Q g 19 Q Q PATENTEB SEP 93975 SHEET 2 UF 5 PATENTED SEP 91975 SHEET 3 OF 5 FIG.5.

FIG.6.

PATENTEDSEP 9:915

sum u or 5 FIG. 7.

FIG.8.

RETURNABLE PACKAGING SYSTEM BACKGROUND OF THE INVENTION This invention relates to packaging system and in particular to a material handling system for the shipment and storage of high volume, high value product components. The invention is described in particular detail with respect to hermetic motor parts, but those skilled in the art will recognize the wide applicability of our invention to other product uses.

Hermetic motors, that is, motors intended to be used in hermetically sealed compressors finding application, for example, in air conditioners and refrigeration systems, are manufactured as component parts and shipped unassembled to the compressor original equipment manufacture. A hermetic motor is known generally in the art as a term embracing motor parts denominated as a stator assembly and a rotor assembly. No shaft, motor shell or end shields are provided with a hermetic motor, as they normally are with other conventional motor types.

The various hermetic motor assemblies are placed in the hermetic compressor by the compressor manufacture. The stator assembly includes a core of magnetic material having an axial opening through it which conventionally is surrounded by an annular array of axially extending slots. The slots contain the motor windings which commonly are constructed from a plurality of wire turns. Those portions of the wire turns that extend axially outwardly along each end of the stator core are known in the art as the winding end turns. These end turns require protection during shipment as any in transit damage to the motor windings or core, in all likelihood, will result in compressor failure in the field. While the rotor assembly, particularly a squirrel cage rotor commonly used in these applications, is less susceptible to certain types of damage, shipping damage can occur, and consequently, these parts too must be protected. Rotor damage often makes the rotor assembly unusable in the application.

An even greater problem in handling hermetic motors involves environmental effects on those motors and entrance of foreign materials, carried by the motor parts, into the compressor system. For example, compressor manufacturers use a number of procedures to ensure that hermetic motor parts are clean, free from rust, and do not inadvertently carry any dirt or other foreign material with them into the assembled compressor. Foreign material in the compressor system can reduce compressor life.

It heretofore has been the industry practice to ship hermetic motor parts in conventional, corrugated paperboard packages. While these packages work well for their intended purposes, they exhibit a number of inherent deficiencies, especially when viewed in the light of the problems inherent in hermetic motor shipping and handling. Thus, the paperboard packages tend to absorb moisture over a period of time. Desiccants, commonly added to the paperboard packages, do protect any metal in the packages for relatively short periods of time. However, desiccants generally used for this purpose become ineffective over longer time periods and storage of hermetic motors in paperboard containers often result in rusted parts. This rust, in turn, must be removed before the parts are suitable for use in a hermetic compressor. In order to protect the winding end turns, the stator assemblies conventionally are supported in the corrugated container on a circular cardboard ring or collar. Both the container itself, and the cardboard ring, have associated with them or help generate considerable cardboard dust within the container. Dust can be generated, for example, by abrasion between the various paperboard surfaces caused by the shifting of the motor parts during shipment. Compressor manufacturers have instituted dust removal procedures but the effectiveness of these procedures long has been questioned. The various components of paperboard packages include the above mentioned collars and a number of cardboard trays between layers of the motor parts, in addition to the conventional top and bottom part of the outer enclosure. All of these packaging components, in addition to the desiccant containers, require disposal after use, generating a considerable waste removal problem.

A number of expedients have been tried in an attempt to alleviate the above deficiencies. The cardboard collars were replaced with plastic collars in an attempt to solve the corrugated dust condition of the shipping containers. While the plastic collars did tend to reduce corrugated paperboard dust, they did not eliminate it and the same cleansing procedures for dust removal were required by the original equipment manufacturers. The plastic collars, of course, did nothing to prevent the entrance or absorption of moisture through the paperboard containers which results in rusted motor parts.

Our invention eliminates prior art problems associated with hermetic motor packaging. The package of this invention is a combination of structural plastic parts, designed to provide optium strength, durability, cleanliness and moisture protection during storage of the component motor parts. All packaging material is intended to be returnable to the initial shipper. There is no waste disposal after the package is unloaded. The empty containers telescope to fifty percent of their full load height. Partially filled containers can be resealed quickly and stored for future use.

One of the objects of this invention is to provide a returnable packaging system.

Another object of this invention is to provide a packaging system that includes an environmental shield for protecting the packaged parts from their environment.

Another object of this invention is to provide a packaging system having no waste material, all packaging material being returnable.

Still another object of this invention is to provide a packaging system having a reduced size when empty.

Other objects of this invention will be apparent to those skilled in the art in light of the following description and accompanying drawings.

SUMMARY OF THE INVENTION In accordance with this invention, generally stated, a packaging system includes a product package having a cover part and a container bottom part. Inflatable sealing means are provided between the cover part and the container bottom part which functions as an environmental seal for the system. The bottom part has a pallet attached to it to facilitate mechanized handling. In its loaded state, container strap means are placed about the interconnectable cover part and container bottom part to lock them against the sealing means. The preferred embodiment also utilizes interlocking trays to define a plurality of product levels within the package.

BRIEF DESCRIPTION OF THE DRAWINGS In the drawings, FIG. 1 is a view in perspective of one illustrative embodiment of packaging system of this invention;

FIG. 2 is a sectional view taken along the line 2-2 of FIG. 1;

FIG. 3 is a view in perspective of the deflated sealing means used in conjunction with the packaging system of FIG. 1',

FIG. 4 is an enlarged sectional view taken along the line 4-4 of FIG. 3;

FIG. 5 is a top plan view of the top cover part illustrated in FIG. 1;

FIG. 6 is a view in side elevation of the top cover part, shown in FIG. 5;

FIG. 7 is a top plan view of the bottom container part utilized in conjunction with the packaging system of FIG. 1;

FIG. 8 is a view in side elevation, taken along the line 8-8 of FIG. 7;

FIG. 9 is a top plan view of one illustrative embodiment of a tray compatible with the packing system of FIG. 1;

FIG. 10 is a view in side elevation, partly broken away, and partly in section, taken along the line 1010 of FIG. 9;

FIG. 11 is a view in side elevation, partly broken away, taken along the line 11-11 of FIG. 9;

FIG. 12 is an enlarged plan view, partly broken away, taken about the area 1212 of FIG. 9',

FIG. 13 is an enlarged sectional view taken along the line 13-13 of FIG. 9; and

FIG. 14 is a sectional view taken along the line 14l4 of FIG. 9.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now to FIGS. 1 and 2, reference numeral 1 indicates the package of this invention. The package 1 includes a cover part 2, a bottom container part 3, a pallet portion 4 and a plurality of trays 5.

The cover part 2 is rectangular in plan having a top 6 and side walls 7, 8, 9 and 10, integrally formed with the top 6, and extending downwardly from it, as best seen in FIGS. 5 and 6. The cover part 2 and the individual trays 5 preferably are vacuum formed parts constructed from a high density, low-melt index, narrow molecular weight distribution polyethylene material. As will be recognized by those skilled in the art, polyethylene formations of any given density can vary in the percentage of long, medium and short chain molecules contained in them. The degree and nature of the chain length profile is referred to as molecular weight distribution. If the resin is made up mostly of chains of the same length, the distribution is called narrow. Narrow resins generally exhibit linear flow properties which reduce stress levels during molding and allow for the production of large parts without warpage. Other materials are compatible with the broader aspects of this invention.

Top 6 has a plurality of ridges 11 formed in it. The ridges 11, while appearing decorative in the embodiment illustrated, in fact function to strengthen the cover 2. Each of the side walls 7, 8, 9 and 10 have outwardly extending edge 12 formed in them, integral with the respective side walls. The four lower corners of the contiguous side walls 7, 8, 9 and 10 are cut away, thereby defining a plurality of openings 13 in each of the lower corners of the cover part 2, as best observed in FIG. 1. The functions of the edge 12 and the openings 13 are important in the use of the package 1. The openings 13 permit independent movement of the side walls 7, 8, 9, and 10 with respect to one another and to the top 6. The edge 12 provides an area for attachment of a container band 14 which is pulled tightly about the package 1, as explained in detail hereinafter.

Container part 3 includes a bottom wall 15 and side walls l6, 17, 18 and 19. The container part 3 is rectangular in plan and is sized so that the cover part 2 may be interconnected with it to define a chamber 50. In the embodiment illustrated, the cover part 2 is intended for mounting over the container part 3, although other embodiments of our invention may reverse this relationship. The container part 2 also is a thermoformed part made from a suitable acrylonitrile-butadiene-styrene material. The side walls 16, 17, 18 and 19 are formed integrally with the bottom wall 15 and extend upwardly from it. The bottom wall 15 includes a plurality of recesses 20 formed integrally with but extending downwardly from the plane of the bottom wall 15. Recesses 20 are utilized to secure the pallet 4 to the container part 3 as explained in detail hereinafter.

A lip 21 projects outwardly from and extends about the perimeter of the container part 3. The lip 21 is formed integrally with each of the side walls 16, 17, 18 and 19 and functionally defines, along with the side walls, a mounting surface 51. An inflatable seal 22 is attached to the container part 3 along the surface 51, as is best seen in FIGS. 2 and 4.

The side walls 16, 17, 18 and 19 have a plurality of vertical ribs 23 formed in them. As with the ridges 11, the ribs 23 provide additional structural rigidity to the container part 3. In addition, however, each of the ribs 23 has a face 24 a plurality of which delimit a straight, vertical plane along the interior surface of the respective side walls. This vertical plane is important in that it helps restrict movement within the chamber by the plurality of trays 5, later described in detail.

Referring now to FIGS. 3 and 4, it is observed that the seal 22 generally is rectangular in plan. The seal 22 includes an outer wall 53 and an inner wall 54 formed in a continuous loop so as to define an air chamber 28. Outer wall 53 has a projection 26 extending outwardly from it.

The seal 22 design gives both an inflatable and a lip seal. Preferably, the seal 22 is constructed of Neoprene which imparts long life and an inflation capability to the seal 22. In order to facilitate inflation and deflation of the seal 22, a valve 29 is connected to the chamber 28. Valve 29 is a conventional means for inflating or deflating the chamber 28, and a variety of valve configurations may be used in conjunction with the package 1. In use, the seal 22 is attached to the container part 3 and in particular, to the sides 16, 17, 18 and 19 and the lip 21 by any convenient method. Epoxy or other adhesive substance works well for the attaching method. A number of seal 22 designs are available commercially, the seal shown and described being merely illustrative of that variety.

An individual one of the trays 5 is shown in FIGS. 9 through 14 of the drawings. As there illustrated, tray 5 generally is rectangular in plan and is a thermal formed polyethylene part. The particular tray pictured is adapted to permit loading of 72 hermetic stator assemblies 55 having a core 56 constructed from a substantially square lamination design. While the tray 5 is described herein with respect to a particular lamination design, other tray configurations will be envisioned by those skilled in the art, and the trays 5 may be constructed so as to accommodate other lamination designs, motor types, or rotor assemblies, for example. Each tray 5 includes a surface 30 having a downwardly turned flange 31 integrally formed with it, and a side wall 27. The surface 30 of the tray 5 is constructed so as to define a plurality of cavities 32. The cavities 32 are intended to receive a mass of end wire turns 25 of the motor windings. The cavities 32 extend downwardly from the surface 30 and are of sufficient depth to prevent end wire turns 25 contact with any part of the tray 5. The peculiar shape of the cavities 32 are useful in preventing rotation of the stator assembly 55 in the tray 5 during shipment. That is, the cavities 32 are designed to receive the end wire turns 25 and to conform, at least partially, to an end view silhouette of the stator assembly 55. Toward that end, the surface 30 of each tray 5 also defines a plurality of support areas 33 which are intended to abut the core 56 of the stator assembly 55. The support area 33 ensures that each stator assembly 55 rests above any other part of the tray 5. The configuration of the tray 5 shown and described cradles the stator assemblies 55 during shipment. However, even if some limited movement of an individual stator assembly 55 takes place, no part of that assembly, except the core 56 will touch any other part of the tray.

Preselected ones of the cavities 32 have either a positive boss 34 or a negative boss 35 formed in it. The bosses 34 and 35 are complimentary to one another and interlock when one tray 5 is inverted and joined with another tray 5 to define a plurality of layers within the package 1. The tray 5 illustrated in FIG. 9 has six of the positive bosses 34, represented by the letter B, and six of the negative bosses 35, represented by the letter A, symmetrically located on respective halfs of the tray 5. As indicated, the trays 5 interlock along the bosses 34 and 35 whenever a first tray 5 is inverted and placed atop a second tray 5.

The pallet portion 4 is attached to the bottom wall of the container part 3 by any convenient method. Again, epoxy or similar adhesive works well. The pallet 4 is a casting constructed from an expanded acrytonitrile-butadienestyrene foam. Other materials are compatible with the broader aspects of our invention. The pallet 4 includes a horizontal wall 37 which is surrounded about its perimeter by an upturned rim 38. The wall 37 also has three integral supports 36 extending downwardly from it. lntegrally formed with the wall 37 are a plurality of recesses 39. The recesses 39 are sized and positioned so that they mate with the recesses of the container part 3, as best seen in FIG. 2. The mating relationship between the recesses 39 and 20 facilitate joinding of the pallet 36 and container part 3 discussed above.

The supports 36, in the embodiment illustrated, extend substantially along one length dimension of the wall 37. However, the supports 36 may assume a variety of configurations. A plurality of individual legs, for example. works well. It is convenient if the supports 36 are spaced laterally from one another to permit package 1 handling by conventional fork lift trucks.

Use of the package 1 of this invention simplifies both packaging, unpacking and handling of hermetic motor parts. The empty, integral container part 3 and pallet 34 combination has a first tray 5 placed in it, surface 30 side up. In this position, the flange 31 abuts the faces 24 of the ribs 23, restricting tray movement during shipment. Thereafter, a plurality of stator assemblies are placed in the cavities 32 either directly from a production line, or from a suitable storage area. As described above, the cavities 32 are designed to protect the end wire turns 25 along a first end of the stator assembly 55. Design variations in the trays 5, of course, will alter the number of stator assemblies 55 carried by an individual tray 5. The tray 5 of the preferred embodiment is capable of storing 72 of the stator assemblies 55 within its confines.

After the first tray 5 is loaded, a second tray 5 is inverted and placed over the plurality of stator assemblies 55. The second tray 5 tends to encapsulate the stator assemblies 55 carried by the first tray 5 as the second tray 5 protects the end wire turns 25 along a second end of each the stator assemblies 55.

A third tray 5 then is placed in the container 3, again, surface 30 side up. Because of the tray 5 construction discussed above, the bosses 34 and 35 of the second and third trays 5 can be interlocked, one within the other. The loading procedure is continued. trays 5 forming the top of one layer for the stator assemblies 55 interlocking with the trays 25 from the bottom of the succeeding layer as loading continues. Theoretically, any number of layers of the stator assemblies 55 may be thus arranged within the package 1. Practical considerations, however, limit the number of layers so that the total weight to the package 1 may be handled easily during shipment. Four layers of the stator assemblies 55 are a practical limit with the substantially square lamination discussed above. After the fourth layer of the stator assemblies 55 is placed within the container part 3, a final tray 5 is inverted and placed over the end turns. The cover part 2 is placed over the filled container part 3 and the shipping band 14 is placed about the combination and drawn tightly about the package 1. It should be noted that the cover part 2 abuts the final tray 5 of the package 1 while the first tray 5 abuts the container part 3. Consequently, the various layers are fixed both vertically and horizontally within the chamber 50. Seal 22 is inflated and because of the openings 13 in the cover part 2, the sides 7, 8, 9 and 10 of the cover part 2 are able to meet the outwardly expanding seal 22 and bow slightly, as is best seen in FIG. 2. The seal 22 engagement with the cover 2 provides an effective environmental shield for the package 1 in that both the cover part 2 and container part 3 and seal 22 are impervious to moisture or other pollutants and are capable of protecting the material contained in the package 1 over extended periods of tlme.

A number of the packages 1 may be stacked one atop another, during transit or storage. Again, practical considerations dictate the number of packages 1 that may be so arranged. Generally, three of the packages 1 are handled easily with conventional mechanized handling equipment.

The package 1 is opened by removing the band 14 and deflating the seal 22. The lid is laid aside and the trays may be placed inside of it, as they are emptied in the unpacking process. When the Container part 3 is empty, the trays 5 are returned to it and the cover part 2 is placed over the container part 3. The storage of the trays 5 in the package 1 protects them from damage and possible contamination during the return cycle. It may be observed mentally, in FIG. 2, that the height of an empty package 1 is reduced appreciably from the overall height of a fully loaded package 1. This reduced height simplifies both the storage and return shipment of the empty package 1.

Numerous variations, within the scope of the appended claims, will be apparent to those skilled in the art in light of the foregoing description and accompanying drawings. Thus, the design of the package 1 may be varied. For example, the opening 13 may be eliminated and replaced by a corrugated portion of the cover 2, or a solid cover may be utilized. A solid cover, however, does not facilitate bowing of the side walls after the band 14 is tightened about the package 1. The design of the ribs in the cover part 2 may be modified. The cover 2 also may have horizontal or vertical corrugations in it for strength, rather than the radial ribs shown and described. The pallet 4 may have a plurality of openings in it, if desired. While outside storage of empty packages 1 is both feasible and convenient, water sometimes enters along the rim 38 between the pallet 4 in the container part 3. The water then flows into the void between the supports 36 and the container part 3. Openings along the supports 36 allow drainage of any water that inadvertently enters this area. Both the rim 38 and the edge 12 may be discontinuous about the perimeter of the pallet 4 and the cover part 2, respectively, These variations are merely illustrative.

Having thus described the invention, what is claimed and desired to be secured by Letters Patent is:

l. A packaging system for shipping a plurality of motor parts comprising:

a pallet portion;

a bottom container mounted to said pallet portion, said bottom container being constructed from moisture impervious material, said bottom container including a bottom wall, a first pair of oppositely opposed side walls extending upwardly from said bottom wall, and a second pair of oppositely opposed side walls extending upwardly from said bottom wall;

a cover part of moisture impervious material interconnectable with said bottom container so as to define a chamber, said chamber having a size variable between at least a first size corresponding to a fully loaded condition of said packaging system and a second size corresponding to an unloaded condition of said packaging system, said second size being substantially smaller than said first size, said cover part including a top wall, a first pair of oppositely opposed downwardly extending walls integrally formed with said top wall, a second pair of oppositely opposed downwardly extending walls integrally formed with said top wall, said first and said second pairs of downwardly extending walls being joined to one another and to said top wall at a first end of adjacent ones of said pairs, said first and said second pairs of downwardly extending walls having relief formed in them at a second end of adjacent ones of said pairs;

a plurality of layers of motor parts. the height of said layers being greater than the height of said bottom container in said first size of said chamber, each of said layers comprising a first tray having a plurality of receptacles formed in it for supportingly receiving a first end of respective ones of said motor parts, a plurality of motor parts carried along said receptacles, and a second tray having a plurality of receptacles in it for receiving a second end of respective ones of said motor parts, the edges of trays of the said layers within said bottom container abutting at least a portion of said first and said second pairs of oppostely opposed side walls of said bottom container, thereby restricting horizontal movement of said layers within said bottom container, the uppermost tray of said layer plurality in said first size of said chamber abutting said cover part, thereby restricting vertical movement of said trays;

moisture impervious sealing means between said cover part and said bottom container, said sealing means being releasably inflatable between at least a first position and a second position; and

means for drawing the oppositely opposed walls of said cover part against said sealing means, said relief means permitting the oppositely opposed walls of said cover part to be drawn against said sealing means while the top wall remains in abuttment with the uppermost tray of said layer plurality in the first size of said chamber.

2. The packaging system of claim 1 wherein said bottom container, said cover part and said trays are constructed from acrylonitrile butodiene styrene.

3. The packaging system of claim 2 wherein the junction of adjacent ones of said pairs of downwardly extending walls of said cover part are cut-away along their second ends, said cut-away defining said relief means and permitting independent movement of said downwardly extending walls.

4. The packaging system of claim 3 wherein the top wall of said cover part has a plurality of ridges formed in it, and an outwardly extending lip integrally formed along said second end of said downwardly extending walls.

5. The packaging system of claim 4 wherein said drawing means extends circumferentially about said packaging system along said lip.

6. The packaging system of claim 5 wherein the second tray of one layer of said layer plurality and the first tray of the succeeding layer of said layer plurality inter lock with one another.

7. A packaging system for shipping a plurality of parts comprising:

a pallet portion;

a bottom container mounted to said pallet portion, said bottom container being constructed from moisture impervious material, said bottom con tainer including a bottom wall, a first pair of oppositely opposed side walls extending upwardly from said bottom wall. and a second pair of oppositely opposed side walls extending upwardly from said bottom wall;

a cover part of moisture impervious material interconnectable with said bottom container so as to define a chamber, said chamber having a size variable between at least a first size corresponding to a fully loaded condition of said packaging system and a second size corresponding to an unloaded condition of said package, said second size being substantially smaller than said first size, said cover part including a top wall, a first pair of oppositely opposed downwardly extending walls integrally formed with said top wall, a second pair of oppositely opposed downwardly extending walls integrally formed with said top wall, said first and said second pairs of downwardly extending walls being joined to one another and to said top wall at a first end of adjacent ones of said pairs, said first and said second pairs of downwardly extending walls having relief formed in them at a second end of adjacent ones of said pairs;

plurality of part layers, the height of said layers being greater than the height of said bottom container in said first size of said chamber, each of said layers comprising a first tray having a plurality of receptacles formed in it for supportingly receiving a first end of respective ones of said parts, a plurality of parts carried along said receptacles, and a second tray having a plurality of receptacles in it for receiving a second end of respective ones of said parts, the edges of trays of the said layers within said bottom container abutting at least a portion of said first and said second pairs of oppositely opposed side walls of said bottom container, thereby restricting horizontal movement of said layers within said bottom container, the uppermost tray of said layer plurality in said first size of said chamber abutting said cover part, thereby restricting vertical movement of said trays; moisture impervious sealing means between said cover part and said bottom container, said sealing means being releasably inflatable between at least a first position and a second position; and

means for drawing the oppositely opposed walls of said cover part against said sealing means, said relief means permitting the oppositely opposed walls of said cover part to be drawn against said sealing means while top wall remains in abuttment with the uppermost tray of paid layer plurality in the' first size of said chamber.

8. The packaging system of claim 7 wherein said pallet portion has a plurality of openings in it.

9. The packaging system of claim 7 wherein the top wall of said cover part has an outwardly extending lip integrally formed along said second end of said downwardly extending walls, said drawing means extending circumferentially about said packaging system along said lip. v

10. The packaging system of claim 9 wherein the second tray of one layer of said plurality of part layers and the first tray of the succeeding layer of said plurality of part layers interlock with one another. 

1. A packaging system for shipping a plurality of motor parts comprising: a pallet portion; a bottom container mounted to said pallet portion, said bottom container being constructed from moisture impervious material, said bottom container including a bottom wall, a first pair of oppositely opposed side walls extending upwardly from said bottom wall, and a second pair of oppositely opposed side walls extending upwardly from said bottom wall; a cover part of moisture impervious material interconnectable with said bottom container so as to define a chamber, said chamber having a size variable between at least a first size corresponding to a fully loaded condition of said packaging system and a second size corresponding to an unloaded condition of said packaging system, said second size being substantially smaller than said first size, said cover part including a top wall, a first pair of oppositely opposed downwardly extending walls integrally formed with said top wall, a second pair of oppositely opposed downwardly extending walls integrally formed with said top wall, said first and said second pairs of downwardly extending walls being joined to one another and to said top wall at a first end of adjacent ones of said pairs, said first and said second pairs of downwardly extending walls having relief formed in them at a second end of adjacent ones of said pairs; a plurality of layers of motor parts, the height of said layers being greater than the height of said bottom container in said first size of said chamber, each of said layers comprising a first tray having a plurality of receptacles formed in it for supportingly receiving a first end of respective ones of said motor parts, a plurality of motor parts carried along said receptacles, and a second tray having a plurality of receptacles in it for receiving a second end of respective ones of said motor parts, the edges of trays of the said layers within said bottom container abutting at least a portion of said first and said second pairs of oppostely opposed side walls of said bottom container, thereby restricting horizontal movement of said layers within said bottom container, the uppermost tray of said layer plurality in said first size of said chamber abutting said cover part, thereby restricting vertical movement of said trays; moisture impervious sealing means between said cover part and said bottom container, said sealing means being releasably inflatable between at least a first position and a second position; and means for drawing the oppositely opposed walls of said cover part against said sealing means, said relief means permitting the oppositely opposed walls of said cover part to be drawn against said sealing means while the top wall remains in abuttment with the uppermost tray of said layer plurality in the first size of said chamber.
 2. The packaging system of claim 1 wherein said bottom container, said cover part and said trays are constructed from acrylonitrile butodiene styrene.
 3. The packaging system of claim 2 wherein the junction of adjacent ones of said pairs of downwardly extending walls of said cover part are cut-away along their second ends, said cut-away defining said relief means and permitting independent movement of said downwardly extending walls.
 4. The packaging system of claim 3 wherein the top wall of said cover part has a plurality of ridges formed in it, and an outwardly extending lip integrally formed along said second end of said downwardly extending walls.
 5. The packaging system of claim 4 wherein said drawing means extends circumferentially about said packaging system along said lip.
 6. The packaging system of claim 5 wherein the second tray of one layer of said layer plurality and the first tray of the succeeding layer of said layer plurality interlock with one another.
 7. A packaging system for shipping a plurality of parts comprising: a pallet portion; a bottom container mounted to said pallet portion, said bottom container being constructed from moisture impervious material, said bottom container including a bottom wall, a first pair of oppositely opposed side walls extending upwardly from said bottom wall, and a second pair of oppOsitely opposed side walls extending upwardly from said bottom wall; a cover part of moisture impervious material interconnectable with said bottom container so as to define a chamber, said chamber having a size variable between at least a first size corresponding to a fully loaded condition of said packaging system and a second size corresponding to an unloaded condition of said package, said second size being substantially smaller than said first size, said cover part including a top wall, a first pair of oppositely opposed downwardly extending walls integrally formed with said top wall, a second pair of oppositely opposed downwardly extending walls integrally formed with said top wall, said first and said second pairs of downwardly extending walls being joined to one another and to said top wall at a first end of adjacent ones of said pairs, said first and said second pairs of downwardly extending walls having relief formed in them at a second end of adjacent ones of said pairs; a plurality of part layers, the height of said layers being greater than the height of said bottom container in said first size of said chamber, each of said layers comprising a first tray having a plurality of receptacles formed in it for supportingly receiving a first end of respective ones of said parts, a plurality of parts carried along said receptacles, and a second tray having a plurality of receptacles in it for receiving a second end of respective ones of said parts, the edges of trays of the said layers within said bottom container abutting at least a portion of said first and said second pairs of oppositely opposed side walls of said bottom container, thereby restricting horizontal movement of said layers within said bottom container, the uppermost tray of said layer plurality in said first size of said chamber abutting said cover part, thereby restricting vertical movement of said trays; moisture impervious sealing means between said cover part and said bottom container, said sealing means being releasably inflatable between at least a first position and a second position; and means for drawing the oppositely opposed walls of said cover part against said sealing means, said relief means permitting the oppositely opposed walls of said cover part to be drawn against said sealing means while top wall remains in abuttment with the uppermost tray of said layer plurality in the first size of said chamber.
 8. The packaging system of claim 7 wherein said pallet portion has a plurality of openings in it.
 9. The packaging system of claim 7 wherein the top wall of said cover part has an outwardly extending lip integrally formed along said second end of said downwardly extending walls, said drawing means extending circumferentially about said packaging system along said lip.
 10. The packaging system of claim 9 wherein the second tray of one layer of said plurality of part layers and the first tray of the succeeding layer of said plurality of part layers interlock with one another. 